Sunroof has been making noise (creaking, popping) for a while now and I thought it just needed to be adjusted. I took a good look at it this weekend and noticed that the tabs on the actuating arms are cracked (see photo). Took this photo from the passenger side with the sunroof in the vent position.

Has anyone seen this before? Any idea what could cause these to crack like this?

Thanks,
Mike

 

This has happened to my '04 Cooper S as well a couple of years ago, on both sides. I get the same noises, too. I haven't found a fix yet, but haven't looked very hard either. I'll keep an eye on this thread - if the part is available and can easily be replaced I'll definitely do it.

 

Bet it needed a lube for a LONG time.......
It might have been activated when frozen....either lack of lube, or just frozen water some winter...just a WAG.

 

Thanks for the replies...

The parts are not available individually - you have to but the entire frame (cassette) which runs about $1500 or so. The parts themselves are made of Polyoxymethylene (POM) which is very difficult to bond making a repair iffy at best.

It's a California car and has never seen freezing temps. The mechanism itself works great and has never given me any trouble. It's just that freaking noise that's driving me crazy!

Mike

 

Maybe the sunroof was forced open....either broken into or a lostkey/lockout?
you might try a salvage yard yo get the parts....if they can be fitted to the current part.

 

Is this in the front or the back of the glass? I havent seen a stress crack like this before but I believe it was probably caused from binding or lack of lubrication and possibly debris on the tracks. I have seen stress cracks in other areas and that is what usually causes the issues. If you do decide to purchase a new or used cassette and you are in southern california, I can install it for about half of dealer cost. Send me a PM if interested. Good luck!

 

It's in the rear - these are the arms that extend to lift the rear of the glass when it first opens. You can't see it in the pic, but there's also a tab on the inside that holds the glass down when closed. Since it's cracked, it's not holding the glass tight enough, allowing it to move and make noise.

Thanks,
Mike